Front Suspension Housing Buckling Structure for Crash Deformation

Solution Overview

Problem

Existing front vehicle body structures face challenges in balancing the need for the front frame to deform during collisions while maintaining the rigidity required to support the suspension, as conventional methods either compromise on deformation or rigidity.

Innovation Solution

A front vehicle body structure featuring suspension housings with a buckling promoting portion between fixed portions, allowing the suspension housing to buckle and deform while maintaining rigidity, and incorporating bulges to enhance mounting efficiency and deformation promotion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the suspension housing is made rigid to support the suspension, then the suspension support capability is improved, but the front frame deformation capability deteriorates

Engineering Contradiction:

Improvesuspension support capabilityVSAvoidfront frame deformation capability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The suspension housing employs different structural characteristics in different regions: the fixed portions have high rigidity for suspension support, while the buckling promoting portion has reduced rigidity to enable controlled deformation. This local differentiation allows the housing to simultaneously support suspension loads and deform with the front frame during collisions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The suspension housing is segmented into functionally distinct regions: rigid fixed portions for suspension mounting and a deformable buckling promoting portion for collision energy absorption. This segmentation allows each region to independently perform its designated function without interfering with the other.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the suspension housing is made deformable to allow front frame deformation, then the front frame deformation capability is improved, but the suspension support capability deteriorates

Engineering Contradiction:

Improvefront frame deformation capabilityVSAvoidsuspension support capability

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The suspension housing employs different structural characteristics in different regions: the fixed portions have high rigidity for suspension support, while the buckling promoting portion has reduced rigidity to enable controlled deformation. This local differentiation allows the housing to simultaneously support suspension loads and deform with the front frame during collisions.

Inventive Principle:

Principle #3Local quality

3Strength

If the suspension housing is firmly fixed to the front frame, then the suspension support capability is improved, but the front frame deformation capability deteriorates

Engineering Contradiction:

Improvesuspension support capabilityVSAvoidfront frame deformation capability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The suspension housing is segmented into functionally distinct regions: rigid fixed portions for suspension mounting and a deformable buckling promoting portion for collision energy absorption. This segmentation allows each region to independently perform its designated function without interfering with the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The suspension housing employs different structural characteristics in different regions: the fixed portions have high rigidity for suspension support, while the buckling promoting portion has reduced rigidity to enable controlled deformation. This local differentiation allows the housing to simultaneously support suspension loads and deform with the front frame during collisions.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the front frame to deform appropriately during collisions while ensuring the suspension housing provides adequate support and stability, preventing interference with the front frame's deformation and enhancing work efficiency during assembly.

Implementation Method 1

a buckling promoting portion that is provided substantially at a center portion in the front-rear direction of the third inner wall at a position between the first fixed portion and the second fixed portion in the front-rear direction and has a shape extending substantially in the up-down direction with a bend protruding inward in the vehicle width direction and promotes buckling of the suspension housing when a load is applied from the front frame to the suspension housing in the front-rear direction

Methodology Applied

Scientific EffectBuckling:

Data Source

PatentEP3632780B1Front vehicle body structure for vehicle and method of forming the same

Publication Date: 2025.01.08 MAZDA MOTOR CORP

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AI summary

A suspension housing 5 which is provided at a front part of a vehicle and to which a suspension 10 is mounted has a first fixed portion 67 and a second fixed portion 77 that are provided at positions separated from each other in a front-rear direction and each fixed to a front frame 3. The suspension housing 5 further has, at a position between the first fixed portion 67 and the second fixed portion 77 in the front-rear direction, a buckling promoting portion 83d that promotes buckling of the suspension housing 5 when a load is applied from the front frame 3 to the suspension housing 5 in the front-rear direction.